Bed Frame Assembled By Snapping Wedge Inserts into Slots

ABSTRACT

A bed frame includes legs, bars and wooden slats. Each leg has first and second sides that meet each other at an edge. A first slot is disposed on the first side adjacent to the edge, and a second slot is disposed on the second side adjacent to the edge. Each bar has two wedge inserts. A first wedge on a lateral bar fits into the first slot, and a second wedge on a longitudinal bar fits into the second slot. The lateral bar is perpendicular to the leg while the first wedge is lodged in the first slot, and the longitudinal bar is perpendicular to the leg while the second wedge is lodged in the second slot. The first slot and the second slot are disposed between the lateral bar and the longitudinal bar while the first and second wedge inserts are lodged in the first and second slots.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of, and claims priority under35 U.S.C. §120 from, nonprovisional U.S. patent application Ser. No.15/004,762 entitled “Snap Assembly of Mattress Supporting System,” filedon Jan. 22, 2016, the subject matter of which is incorporated herein byreference.

TECHNICAL FIELD

The described embodiments relate to bedding products, and moreparticularly to a folding bed frame and a mattress supporting system.

BACKGROUND INFORMATION

Conventional bed frames are relatively heavy and awkward. FIG. 1 (priorart) shows the structure of a conventional bed frame 10 including twoopposing side rails 11 with a plurality of cross bar members 12extending between the side rails. Bed frame 10 also includes a centerbeam 13 that is parallel to the side rails and located at the center ofthe bed frame in order to provide additional support to a box spring andmattress. The side rails 11 and cross bar members 12 are typicallyformed from elongated pieces of steel having an L-shaped cross-section(also called angle iron). A horizontal flange of each side rail 11supports the box spring, and a vertical flange prevents each side railfrom bending under the weight of the box spring, the mattress and theoccupants of the bed. Thus, the angular arrangement of the side rails isrequired for structural integrity. Edge attachments 14 are screwed tothe ends of the side rails 11 to prevent the box spring from slidingpast the head of the bed frame 10. The edge attachments 14 have sharpmetal edges located at the level of the shins of persons walking aroundthe bed frame 10, for example during assembly. In addition, downwardlyextending support legs typically screw into threaded leg holdersattached to cross bar members 12, center beam 13 and/or side rails 11.The bed frame 10 may support the box spring on loose wooden slatsspanning between the side rails or may directly accommodate the boxspring.

Conventional bed frames are typically assembled at the location of thebed. The assembly process can be cumbersome because it usually involvesmany non-intuitive steps and requires the use of multiple tools. Themanner in which multiple pieces are connected to form the cross barmembers 12 is typically complicated and can require tools. In addition,the support legs must be screwed or bolted to the cross bar members 12or side rails 11. Another shortcoming of conventional bed frames is therelatively heavy weight, due primarily to the weight of the angle ironsfrom which side rails 11 and cross bar members 12 are made. The heavyweight results in higher shipping costs and difficulty of assembly.

Thus, a light-weight bed frame is sought that is less complicated toassemble and does not require tools to connect the components. Theeasily assembled bed frame should nevertheless be sturdy and should fitinside a compact shipping box. The bed frame should prevent the mattressfrom sliding past the head of the bed without using edge attachmentsthat can injure the shins and feet of users walking around the foot ofthe bed frame. SUMMARY

A bed frame assembly for supporting a mattress includes lateral bars,longitudinal bars, support legs and wooden slats. Each support leg hastwo triangular slots, and each bar has two wedge inserts. A firsttriangular slot opens from the first side of a support leg, and a secondtriangular slot opens from a perpendicular, second side of the supportleg. A first wedge insert on a lateral bar fits into the firsttriangular slot. The lateral bar is oriented perpendicular to thesupport leg while the first wedge insert is lodged in the firsttriangular slot. A second wedge insert on a longitudinal bar fits intothe second triangular slot. The longitudinal bar is orientedperpendicular to the support leg while the second wedge insert is lodgedin the second triangular slot. Corresponding wedge inserts andtriangular slots are identified by the same numerals and enable the snapassembly of the bed frame assembly. By matching the numerals displayedon or near corresponding wedge inserts and triangular slots, the usercan intuitively assemble the bed frame assembly by the numbers. Thewooden slats are then placed on ledges on the inner sides of thelongitudinal bars and span between the bars. The wooden slats areattached to one another by fabric ribbons made of hook and loopfastening material. The slats are held in place on the ledges by theribbons that stick to strips of fastening material on the ledges.

Each triangular slot is formed by a bent sheet of metal welded to a sideof a support leg. The angle that the triangular slot forms with the sideof the support leg is approximately equal to the angle made by thecorresponding wedge insert. The first wedge insert has a slanted outersurface that contacts an inside hypotenuse surface of the firsttriangular slot while the first wedge insert is lodged in the firsttriangular slot. In one embodiment, a bent lip projects from the slantedouter surface of the wedge insert and catches on an edge of the insidehypotenuse surface of the triangular slot when the wedge insert iscompletely inserted into the triangular slot. In another embodiment, thefirst wedge insert has a notch that faces the first side of the supportleg while the first wedge insert is lodged in the first triangular slot.The first triangular slot has a shaft at its upper lip along the firstside of the support leg. The shaft fits into the notch when the firstwedge insert snaps into the first triangular slot.

A method of assembling the bed frame assembly starts with the userremoving the four bars, four legs, the wooden slats and the userinstructions from the packing box. The user begins to assemble the bedframe assembly by inserting the wedge insert identified by the numeral“1” into the corresponding triangular slot that is also identified bythe numeral “1”. Then the user inserts the wedge insert marked as “2”into the triangular slot marked “2”. The first wedge insert marked as“2” is disposed on a lower side of a lateral bar of the bed frameassembly. The first triangular slot marked as “2” opens from a firstside of a first support leg of the bed frame assembly. A second side ofthe first support leg is perpendicular to the first side. The firstwedge insert is inserted into the first triangular slot until the firstwedge insert snaps into the first triangular slot.

Then a second wedge insert marked as “3” is inserted into a secondtriangular slot marked as “3”. The second wedge insert is disposed on abottom side of a longitudinal bar of the bed frame, and the secondtriangular slot opens from the second side of the first support leg.When both the first wedge insert marked as “2” is inserted into thefirst triangular slot marked as “2” and the second wedge insert markedas “3” is inserted into the second triangular slot marked as “3”, thelateral bar is perpendicular to the longitudinal bar. Then a third wedgeinsert marked as “4” is inserted into a third triangular slot marked as“4”. The third wedge insert is disposed on the bottom side of thelongitudinal bar, and the third triangular slot is disposed on a secondsupport leg of the bed frame. The user then continues the assembly byinserting wedge inserts into triangular slots both marked with “5”, “6”,“7” and “8”.

In another embodiment, a sturdy, easily assembled bed frame assemblyincludes support legs, lateral bars and longitudinal bars. A support leghas a first side, a second side, a first slot and a second slot. Thefirst side is perpendicular to the second side and meets the second sideat an edge. The first slot is disposed on the first side adjacent to theedge, and the second slot is disposed on the second side adjacent to theedge. A first wedge insert is attached to a lateral bar and fits intothe first slot. The first wedge insert has a first wedge angle that isapproximately equal to a first slot angle formed by the first slot. Inone aspect, the first wedge insert is held in the first slot by frictionwithout using any rotating fastener. In another aspect, the first wedgeinsert snaps into the first slot. While the first wedge insert is lodgedin the first slot, the lateral bar is oriented perpendicular to thesupport leg, and the first wedge insert is disposed between the edge andthe lateral bar. A second wedge insert is attached to a longitudinal barand fits into the second slot. While the second wedge insert is lodgedin the second slot, the longitudinal bar is oriented perpendicular tothe support leg, and the second wedge insert is disposed between theedge and the longitudinal bar.

In yet another embodiment, a bed frame assembly includes a leg, alateral bar and a longitudinal bar. The leg has a first slot and asecond slot. The first slot has a first inner slanted surface, and thesecond slot has a second inner slanted surface. The lateral bar has afirst wedge insert that is adapted to lodge in the first slot. The firstwedge insert has a first slanted outer surface that is adapted tocontact the first inner slanted surface while the first wedge insert islodged in the first slot. The lateral bar is perpendicular to the legwhile the first wedge insert is lodged in the first slot.

The longitudinal bar has a second wedge insert that is adapted to lodgein the second slot. The second wedge insert has a second slanted outersurface that is adapted to contact the second inner slanted surfacewhile the second wedge insert is lodged in the second slot. Thelongitudinal bar is perpendicular to the leg and perpendicular to thelateral bar while both the second wedge insert is lodged in the secondslot and the first wedge insert is lodged in the first slot. Both thefirst slot and the second slot are disposed between the lateral bar andthe longitudinal bar while the first and second wedge inserts are lodgedin the first and second slots. The leg has a first side and a secondside that meet each other at an edge. The first slot is disposed on thefirst side adjacent to the edge, and the second slot is disposed on thesecond side adjacent to the edge.

Further details and embodiments are described in the detaileddescription below. This summary does not purport to define theinvention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate embodiments of the invention.

FIG. 1 (prior art) is a perspective view of a prior art bed frame witheach rail having an L shape.

FIG. 2 is a perspective view of a novel bed frame that is easilyassembled without tools.

FIG. 3 shows the bed frame of FIG. 2 in an unassembled state such as howthe components would appear when a user first removes them from apacking box.

FIG. 4 is a more detailed view of a support leg with triangular slots asshown in FIG. 3.

FIG. 5 illustrates how a wedge insert is inserted into a triangular slotof the support leg of FIG. 4.

FIG. 6 is a flowchart illustrating steps of a method of assembling thebed frame of FIG. 2.

FIG. 7 illustrates how another wedge insert is inserted into atriangular slot of another support leg of the bed frame of FIG. 2.

FIG. 8 shows various stages of the wedge insert of FIG. 7 being insertedinto the triangular slot.

FIG. 9 shows a portion of the bed frame of FIG. 2 after two steps of themethod of FIG. 6 have been performed.

FIG. 10 shows two rolls of wooden slats of the bed frame of FIG. 2 afterthey have been unrolled.

FIG. 11 shows another embodiment of the bed frame of FIG. 2 in which awedge snaps into a slot when a lip on the wedge snaps past an edge ofthe slot.

FIG. 12 is a cross-sectional, schematic view of the wedge insert of FIG.11 having been snapped into a triangular slot.

FIG. 13 shows yet another embodiment of the bed frame of FIG. 2 in whicha wedge snaps into a slot when a notch on the wedge snaps past a shaftof the slot.

FIG. 14 is a cross-sectional, schematic view of the wedge insert of FIG.13 having been snapped into a triangular slot.

FIG. 15 is a perspective view of another embodiment of an easilyassembled bed frame.

FIG. 16 shows the components of the bed frame of FIG. 15 in anunassembled state.

FIG. 17 is a more detailed view of a support leg to which slots areattached as shown in FIG. 16.

FIG. 18 is a view of the support leg and slots of FIG. 17 looking upfrom the bottom of the leg and also showing corresponding wedge insertson lateral and longitudinal bars.

FIG. 19 illustrates how a wedge insert is inserted into a slot of thesupport leg of FIG. 17.

FIG. 20 shows a portion of the bed frame of FIG. 15 after both a lateralbar and a longitudinal bar have been attached to the support leg of FIG.17.

FIG. 21 shows the eight metal components of the bed frame of FIG. 15after they have been assembled and before wooden slats have been placedover the bars.

DETAILED DESCRIPTION

FIG. 2 is a perspective view of a novel bed frame assembly 20 that canbe easily assembled without tools by snapping wedge retention insertsinto triangular slots. Bed frame assembly 20 is a mattress supportingsystem upon which a mattress can be directly placed without anyintervening box springs. Bed frame assembly 20 is light weight butnevertheless sturdy. Most important, bed frame assembly 20 is easily andintuitively assembled without using tools. FIG. 2 shows a twin sizedversion of the mattress supporting system. However, the queen and kingsized versions can be made using the same inventive concepts. Bed frameassembly 20 has only eight metal components. The queen sized version canalso be made from just eight metal pieces, while the king sized versionincludes an additional bar and leg.

Bed frame assembly 20 includes two lateral bars 21-22, two longitudinalbars 23-24 and four support legs 25-28. Each of the support legs 25-28has two triangular slots 29. In addition, bed frame assembly 20 includesten wooden slats 30 that span between the two longitudinal bars 23-24.The ends of the wooden slats 29 rest on metal ledges 31-32 that arewelded to the inner sides of the longitudinal bars 23-24. The metalledges 31-32 are positioned lower on the inner sides of the longitudinalbars 23-24 such that the upper surfaces of the wooden slats 30 are belowthe top sides of the longitudinal bars 23-24 and below the upper sidesof the lateral bars 21-22. The tops of the longitudinal and lateral barsfor a lip around the upper surfaces of the wooden slats 30 on which themattress rests. This lip holds the mattress in place and prevents themattress from sliding past the head or foot of the bed frame withoutusing any edge attachments attached to the longitudinal bars.

FIG. 3 shows bed frame assembly 20 in an unassembled state such as howthe components would appear when the user first removes them from thepacking box. FIG. 3 shows that each support leg 25-28 has two triangularslots. For example, a first support leg 25 includes a first triangularslot 33 and a second triangular slot 34. First support leg 25 has afirst side 35 that is perpendicular to a second side 36. The firsttriangular slot 33 opens from the first side 35, and the secondtriangular slot 34 opens from the second side 36. Thus, the firsttriangular slot 33 extends from the first support leg 25 in a directionperpendicular to the direction in which the second triangular slot 34extends from the first support leg 25. The second support leg 26 has twotriangular slots 37-38; the third support leg 27 has two triangularslots 39-40; and the fourth support leg 28 has two triangular slots41-42. FIG. 3 also shows that each of the bars 21-24 includes two of thewedge retention insert fasteners 43-50. The first lateral bar 21 has twowedge inserts 50 and 43. The first longitudinal bar 23 includes the twowedge inserts 44-45. The second lateral bar 22 includes the two wedgeinserts 46-47, and the second longitudinal bar 24 includes the two wedgeinserts 48-49.

Each wedge insert is identified by a numeral that corresponds to thenumeral displayed on the triangular slot into which the particular wedgeinsert must be inserted in order to assemble the bed frame assembly 20.For example, the numeral “2” is printed on a round label that is stuckto the inner side of the first lateral bar 21, and the same numeral “2”is printed on a round label that is stuck to the inner triangular sideof the first triangular slot 33. By identifying wedge inserts and theircorresponding triangular slots by number, the user can intuitivelyassemble the bed frame by inserting each wedge insert into the correcttriangular slot in the proper order.

For example, the user begins the assembly of the bed frame by insertingthe wedge insert 50 identified by the numeral “1” into the triangularslot 42 also identified by the numeral “1”. Then the user inserts thewedge insert 43 marked as “2” into the triangular slot 33 marked “2”.Next, the user inserts the wedge insert 44 marked as “3” into thetriangular slot 34 marked “3”. The user continues the assembly byinserting wedge inserts into triangular slots both marked with “4”, “5”,“6”, “7” or “8”. Note that the user would have to rotate firstlongitudinal bar 23 by 180° so that the numeral “3” that is displayednear the wedge insert 44 matches the numeral “3” that is displayed onthe triangular slot 34. Similarly, the user would have to rotate secondlongitudinal bar 24 by 180° so that the numeral “7” that is displayednear the wedge insert 48 matches the numeral “7” that is displayed onthe triangular slot 40. Thus, by matching the numerals displayed on ornear the wedge inserts and triangular slots, the user can intuitivelyassemble the bed frame assembly 20 by the numbers.

FIG. 4 is a more detailed view of support leg 28 to which triangularslots 41-42 are attached. The user begins assembling bed frame assembly20 by inserting the corresponding wedge insert into the triangular slot42 on which the numeral “1” is displayed. In this embodiment, a roundsticker with the numeral “1” is stuck with adhesive to the triangularside 51 of triangular slot 42 that will face towards the inside of bedframe assembly 20. Triangular slot 42 is formed from a bent sheet ofmetal welded along two edges to a side of support leg 28. The sheet ofmetal is cut so that the upper lip 52 of triangular slot 42 isperpendicular to the side of support leg 28. Triangular slot 42 forms awedge-shaped pocket on the side of support leg 28 with a rectangularslot opening. The diagonal surface on the inside of the pocket forms aninside hypotenuse surface 53 of triangular slot 42. When a wedge insertis lodged in triangular slot 42, a slanted outer surface of the wedgeinsert contacts inside hypotenuse surface 53.

FIG. 5 illustrates how wedge insert 50 is pushed down into triangularslot 42 in the first step of assembling bed frame assembly 20. In thisembodiment, a round sticker with the numeral “1” is stuck with adhesiveto the inner side of lateral bar 21 above wedge insert 50. The numeral“1” displayed above wedge insert 50 identifies the wedge as beingassociated with triangular slot 42. FIG. 5 shows inside hypotenusesurface 53 over which the slanted outer surface 54 of wedge insert 50slides as the wedge insert is being inserted into triangular slot 42.For example, wedge insert 50 can be pushed down into triangular slot 42by stamping the heal of the user's shoe on the upper side 55 of lateralbar 21 above wedge insert 50. In one embodiment, the friction of wedgeinsert 50 being lodged in triangular slot 42 retains the wedge in theslot and attaches lateral bar 21 to support leg 28. No rotatingfastener, such as a screw, bolt or pin, is used to hold wedge insert 50in place in triangular slot 42. Wedge insert 50 has no moving parts.Wedge insert 50 is formed from a bent sheet of metal welded to the lowerside of lateral bar 21. The vertical side of wedge insert 50 that facesthe end of the bar is open. The vertical edges of the metal sheet thatface the end of the bar contact the side of support leg 28 when wedgeinsert 50 is lodged in triangular slot 42.

FIG. 5 shows that lateral bar 21 is hollow and has a rectangular crosssection. In fact, all of the lateral and longitudinal bars 21-24 and thesupport legs 25-28 are made from hollow, rectangular metal bars. Thehollow, rectangular metal construction of the bars provides a strongerstructure with less weight. The hollow, rectangular metal bars providestronger structures than would solid bars of the same weight of metal.

FIG. 6 is a flowchart illustrating the next steps 56-58 of the method ofassembling bed frame assembly 20. The steps 56-58 of the method of FIG.6 are described in relation to the components of bed frame assembly 20shown in FIG. 7. In a next step 56, a first wedge insert 43 that isdisposed on the lower side 60 of lateral bar 21 is inserted into a firsttriangular slot 33 that opens from a first side 61 of first support leg25. First triangular slot 33 is identified by a first numeral “2”displayed on the first triangular slot, and first wedge insert 43 isidentified by the same first numeral “2” displayed near the wedge. Thefirst side 61 is perpendicular to a second side 62 of first support leg25, and a second triangular slot 34 opens from the second side 62. Firstwedge insert 43 has a first slanted outer surface 63 that contacts afirst inner hypotenuse surface 64 of first triangular slot 33 when firstwedge insert 43 is lodged in first triangular slot 33. Despite the factthat first wedge insert 43 does not have a wedge tip, insert 43 isnevertheless wedge-shaped and has a first wedge angle W, as shown inFIG. 7. First triangular slot 33 forms a first slot angle, which is theangle between the slanted outer surface of slot 33 and the first side 61of first support leg 25. FIG. 7 shows that the first slot angle isapproximately equal to the first wedge angle W.

FIG. 8 shows various stages of first wedge insert 43 being inserted intofirst triangular slot 33. The left side of FIG. 8 shows first wedgeinsert 43 partially inserted into first triangular slot 33 with firstslanted outer surface 63 sliding along first inner hypotenuse surface 64of first triangular slot 33. The right side of FIG. 8 shows first wedgeinsert 43 nearly completely inserted into first triangular slot 33. Aconsumer who is assembling bed frame 20 can completely insert firstwedge insert 43 into first triangular slot 33 such that the wedge locksinto the slot by stamping the consumer's foot on the upper side 55 oflateral bar 21 above wedge insert 43. Thus, first wedge insert 43 is ameans for attaching lateral bar 21 to first triangular slot 33 usingfriction and without using any rotating fastener or tools.

In step 57, second wedge insert 44 that is disposed on a bottom side 65of longitudinal bar 23 is inserted into second triangular slot 34.Second triangular slot 34 is identified by a second numeral “3”displayed on the second triangular slot, and second wedge insert 44 isidentified by the same second numeral “3” displayed near the wedge.Second wedge insert 44 has a second slanted outer surface 66 thatcontacts a second inner hypotenuse surface 67 of second triangular slot34 when second wedge insert 44 is lodged in second triangular slot 34.

FIG. 9 shows a portion of bed frame assembly 20 after steps 56-57 havebeen performed. By connecting wedge 43 to slot 33 and wedge 44 to slot34, both lateral bar 21 and longitudinal bar 23 are connected to supportleg 25. By connecting wedges and slots with matching numerals innumerical order, a user who is assembling bed frame 20 is intuitivelydirected to connect the appropriate components to each other. Forexample, no user directions are necessary to instruct the user toconnect support leg 28 to lateral bar 21, and then lateral bar 21 tosupport leg 25, and then support leg 25 to longitudinal bar 23, etc. Byconnecting the corresponding wedges and slots in numerical order, thebars and legs of bed frame 20 are necessarily connected in the properorder. Assembling bed frame assembly 20 by the numbers does not requireeither detailed user instructions or tools.

In step 58, a third wedge insert 45 that is disposed on the bottom side65 of longitudinal bar 23 is inserted into a third triangular slot 37that is located on a second support leg 26. In subsequent steps, thewedge inserts of lateral bar 22 and longitudinal bar 24 are insertedinto the corresponding triangular slots on support legs 26-28. After theeight metal components of the bed frame 20 are assembled, the two rollsof wooden slats 30 are rolled out to span between the ledges 31-32 onthe longitudinal bars 23-24. The upper surfaces of ledges 31-32 arecovered with strips 68 of hook and loop fastening material, such asVelcro®, which is used to hold the slats 30 in place. A strip 68 offastening material on ledge 31 is apparent in FIGS. 7-9.

FIG. 10 shows the two rolls of slats 30 after they have been unrolled.The slats 30 are wooden planks about three feet long and three incheswide. The ten wooden slats 30 are attached to each other near their endsby ribbons 69 made of strong synthetic fabric. In this embodiment, twosets of five slats are connected together. The ribbons 26 are attachedto the bottom side of each slat 30, for example by staples, so that theslats can be rolled up or stacked flat against each other as shown inFIG. 3. In the assembly step, the slats 30 are expanded out in parallelbetween the longitudinal bars 23-24 as shown in FIG. 2. The ends ofwooden slats 30 rest on the support ledges 31-32 that are attached tothe insides of the bars 23-24. Wooden slats 30 are shown in FIG. 10 asflat boards. In another embodiment, however, wooden slats 30 are bowedsuch that they rest on support ledges 31-32 but bow upwards between thebars 23-24. The bowed slats can be stacked all in the same bowedorientation.

FIG. 11 shows another embodiment of bed frame assembly 20 in which thewedge inserts exhibit an enhanced snap when they are completely insertedinto the triangular slots. FIG. 11 illustrates how a first wedge insert70 is inserted into a first triangular slot 71 until the insert 70 snapsinto the 71. The first wedge insert 70 shown in FIG. 11 has a triangularside 72 that more closely resembles a triangle than does the side 73 offirst wedge insert 43 in FIG. 7. Consequently, the slanted outer surface74 of first wedge insert 70 is longer than the first slanted outersurface 63 of first wedge insert 43 in FIG. 7. A bent lip 75 projectsfrom the bottom end of the longer slanted outer surface 74 and catcheson a lower edge 76 of the inside hypotenuse surface 77 when first wedgeinsert 70 is completely inserted into first triangular slot 71. Thelower edge 76 is moved away from the first side 61 of first support leg25 by making a cutout at the bottom of the slanted surface of firsttriangular slot 71. First wedge insert 70 lodges into place in firsttriangular slot 71 when the bent lip 75 snaps past the lower edge 76 ofthe inside hypotenuse surface 77 as wedge 70 is completely inserted intoslot 71.

FIG. 12 is a cross-sectional, schematic view of first wedge insert 70having been snapped into first triangular slot 71. When first wedgeinsert 70 is snapped into first triangular slot 71, the bent lip 75projects out of the cutout at the bottom of the slanted surface of firsttriangular slot 71.

FIG. 13 shows yet another embodiment of bed frame assembly 20 in whichthe wedge inserts achieve an enhanced snap when they are lodged in thetriangular slots. FIG. 13 illustrates how a wedge insert 78 on lateralbar 21 snaps into a triangular slot 79 on support leg 28. The wedgeinsert 78 has a notch 80-81 in each of its triangular sides 82-83. Eachnotch 80-81 of wedge insert 78 faces the side 84 of support leg 28 onwhich triangular slot 79 is mounted. Triangular slot 79 has a shaft 85(not visible in FIG. 13) that fits into each notch 80-81 when wedgeinsert 78 is completely inserted into triangular slot 79.

FIG. 13 shows the analogous shaft 86 on the second triangular slot 87 onsupport leg 28. Shaft 86 is part of the bent sheet of metal from whichtriangular slot 87 is made and is formed by making an additional bend inthat sheet. The sheet of metal is cut so that shaft 86 is a narrowsection that projects from the remainder of the shape of the sheet.Triangular slot 87 is then formed from the bent sheet by welding the twovertical edges to the side 88 of support leg 28. The shaft 86 is alsowelded to the side 88 of support leg 28. Returning to triangular slot79, each notch 80-81 of wedge insert 78 snaps past the shaft 85 andwedges insert 78 into slot 79 as the slanted outer surface 89 of wedgeinsert 78 is slid down along the inside hypotenuse surface 90 oftriangular slot 79. The vertical edges 91-92 of the open vertical sideof wedge insert 78 are pressed against the side 84 of support leg 28 onwhich triangular slot 79 is mounted.

FIG. 14 is a cross-sectional, schematic view of wedge insert 78 havingbeen snapped into triangular slot 79. When wedge insert 78 is snappedinto triangular slot 79, the notches 80-81 are prevented from movingback up and out of triangular slot 79 by the shaft 85.

Bed frame assembly 20 is manufactured by stamping out the appropriatelyshaped metal sheets that are then bent and welded to the bars 21-24 andsupport legs 25-28 to form the wedge inserts 43-50 and triangular slots33-34 and 37-42. Then the ledges 31-32 are welded to the longitudinalbars 23-24, and strips 68 of hook and loop fastening material are gluedto the ledges 31-32. Stickers with the appropriate numerals are thenstuck to the triangular slots and near or on the wedge inserts. The endsof the slats 30 are then connected by ribbons 69 made of strongsynthetic fabric. Finally, the bed frame assembly 20 is assembled in thefactory to ensure that all of the components fit properly.

After the test assembly in the factory, first wedge insert 43 must beremoved from first triangular slot 33, the second wedge insert 44 mustbe removed from the second triangular slot 34, and the other wedgeinserts must be removed from their corresponding triangular slots. Thenthe lateral bars 21-22, the longitudinal bars 23-24, the support legs25-28 and the wooden slats 30 are inserted into a packing box. In analternative embodiment, user instructions are also inserted into thepacking box that instruct the user of the assemblable bed frame assembly20 to insert the first wedge insert 43 into the first triangular slot 33and to insert the second wedge insert 44 into the second triangular slot34. In addition, the instructions instruct the user to place the woodenslats 30 between the first longitudinal bar 23 and the secondlongitudinal bar 24. And the instructions indicate that the mattressshould be placed on the wooden slats.

FIG. 15 is a perspective view of another embodiment of a sturdy bedframe assembly 93 that can be easily assembled without tools byinserting wedge inserts into slots. The wedge inserts of assembly 93 arenot attached below the bars, however, and are not visible from the sidesof the bed frame assembly. The wedge inserts are attached to the ends ofthe bars on the inner sides so that only the bars and the leg supportsare visible after assembly from the sides of the bed frame.

FIG. 15 shows bed frame assembly 93 in an assembled state. A mattresscan be placed directly on bed frame assembly 93 without any interveningbox springs. Although FIG. 15 shows a twin sized version of the bedframe assembly 93, queen and king sized versions can be made using thesame wedge inserts and slots. Bed frame assembly 93 has only eight metalcomponents. The queen sized version can also be made from just eightmetal pieces, while the king sized version includes an additional barand legs.

Bed frame assembly 93 includes two lateral bars 94-95, two longitudinalbars 96-97 and four support legs 98-101. Each of the support legs 98-101has two slots, and each of the bars 94-97 has two wedge inserts. In FIG.15, two wedge inserts 102-103 are labeled on support leg 98, and twowedge inserts 104-105 are labeled on support leg 101. In addition, bedframe assembly 93 includes twelve wooden slats 106 that span between thetwo longitudinal bars 96-97. The ends of the wooden slats 106 rest onmetal ledges 107-108 that are welded to the inner sides of thelongitudinal bars 96-97. Strips of hook-and-loop fastening material holdthe wooden slats 106 to the ledges 107-108. For example, a fabric ribbonof hooks is glued to ledge 107, and a fabric ribbon of loops is stapledto the ends of the slats 106. The hook strip on the bar then attaches tothe loop strip on the slats.

The metal ledges 31-32 are positioned lower on the inner sides of thelongitudinal bars 96-97 such that the upper surfaces of the wooden slats106 are below the top sides of the longitudinal bars 96-97 and below theupper sides of the lateral bars 94-95. The tops of the longitudinal andlateral bars form a lip around the upper surfaces of the wooden slats106 on which the mattress rests. This lip holds the mattress in placeand prevents the mattress from sliding past the head or foot of bedframe assembly 93 without using any edge attachments attached to thelongitudinal bars.

FIG. 16 shows bed frame assembly 93 in an unassembled state such as howthe components would appear when the customer first removes them fromthe packing box in which they were shipped to the customer. FIG. 16shows that each support leg 98-101 has two slots. For example, firstsupport leg 98 has a first slot 109 and a second slot 110. Support legs99-101 have slots 111-116. First support leg 98 has a first side 117that is perpendicular to a second side 118. First side 117 meets secondside 118 at edge 119. The first slot 109 is attached to the first side117, and the second slot 110 is attached to the second side 118. Thus,the first slot 109 extends from the first support leg 98 in a directionperpendicular to the direction at which the second slot 110 extends fromthe first support leg 98. The second support leg 99 has two slots113-114; the third support leg 100 has two slots 115-116; and the fourthsupport leg 101 has two slots 111-112. FIG. 16 also shows that each ofthe bars 94-97 includes two wedge retention insert fasteners. Forexample, the first lateral bar 94 has two wedge inserts 102 and 104. Thefirst longitudinal bar 96 has two wedge inserts 103 and 120. The secondlongitudinal bar 97 has two wedge inserts 105 and 121.

FIG. 16 also shows the fabric ribbons 135 of hook-and-loop fasteningmaterial that are attached to the ends of the wooden slats 106. Thefabric ribbons attach the wooden slats in two groups of six to oneanother and allow the slats to be rolled out over complementary ribbonsof fastening material on the ledges 107-108 after the metal portions ofthe bed frame assembly 93 have been assembled.

In a manner similar to that employed with bed frame assembly 20, eachwedge insert of bed frame assembly 93 is identified by a numeral thatcorresponds to the numeral displayed on the slot into which theparticular wedge insert must be inserted in order to assemble theassembly. Identifying wedge inserts and their corresponding slots bynumber enables the user intuitively to assemble the bed frame byinserting each wedge insert into the correct slot.

FIG. 17 is a more detailed view of support leg 98 to which slots 109-110are attached. First slot 109 is formed from a bent strip of metal weldedalong two edges to first side 117 of support leg 98. The strip of metalis cut in a pattern so that after being bent and welded to first side117, the upper lip 122 of slot 109 is perpendicular to the first side.Slot 109 has a rectangular slot opening and a slanted side 123 oppositefirst side 117 of leg 98. There is an inner slanted surface 124 on theinside of the slanted side 123 of the first slot 109. FIG. 17 shows thatfirst slot 109 is disposed on first side 117 adjacent to edge 119, andsecond slot 110 is disposed on second side 118 adjacent to edge 119.First slot 109 extends across approximately one half of the width offirst side 117 allowing lateral bar 94 to occupy the other half of thewidth when first wedge insert 102 is lodged in first slot 109. Thus,support leg 98 is approximately twice as wide as lateral bar 94.

FIG. 18 is a view of support leg 98 looking up from the bottom of theleg. Slots 109-110 are seen from the bottom. Because side 123 of firstslot 109 slants upward and outward, the rectangular opening at thebottom of slot 109 is smaller than the rectangular opening surrounded byupper lip 122 of slot 109. In FIG. 18, first slot 109 is shown from thesmaller bottom rectangular opening. FIG. 18 also shows a bottomperspective view of first wedge insert 102 attached to lateral bar 94,and second wedge insert 103 attached to longitudinal bar 96. The wedgeinserts 102-103 are welded at the ends of the bars 94 and 96.

First wedge insert 102 is formed by bending a sheet of metal into aU-shape, which is then welded to a bent plate 125. The arms of theU-shape form tongues 126-127 that are connected by a slanted side. Eachof the insert tongues 126-127 has a slanted edge where the tongue meetsthe outer slanted surface 128 of the slanted side. The bent plate 125 isthen welded to the inner side of lateral bar 94 at the end of the bar.When first wedge insert 102 is lodged in slot 109, the outer slantedsurface 128 of first wedge insert 102 contacts and slides along theinner slanted surface 124 of first slot 109.

Second wedge insert 103 is made in an analogous manner. Insert tongues129 are formed by bending a sheet of metal into a U-shape, which is thenwelded to a bent plate 130. Insert tongues 129 are connected by aslanted side that has an outer slanted surface 131. The bent plate 130is welded to the inner side of longitudinal bar 96 at the end of thebar. The ledge 107 does not extend along the entire length oflongitudinal bar 96 but rather ends before the location where secondwedge insert 103 is welded to the inner side of the bar. When secondwedge insert 103 is lodged in slot 110, the outer slanted surface 131 ofsecond wedge insert 103 contacts and slides along the inner slantedsurface 132 of second slot 110.

FIG. 19 illustrates how first wedge insert 102 is pushed down into firstslot 109 in a first step of assembling bed frame assembly 93. As firstwedge insert 102 is inserted into first slot 109, the slanted edges ofinsert tongues 126-127 slide down over the inner slanted surface 124 offirst slot 109. When first wedge insert 102 is lodged in slot 109, theouter slanted surface 128 and the slanted edges of insert tongues126-127 press against the inner slanted surface 124 of first slot 109,and the vertical edges of insert tongues 126-127 are pressed onto firstside 117. Wedge insert 102 can be pushed down into first slot 109 bystamping the heal of one's shoe on the upper side 133 of lateral bar 94adjacent to first wedge insert 102. The friction of the insert tongues126-127 being pressed between the inner slanted surface 124 and thefirst side 117 retains the first wedge insert 102 in the first slot 109.First wedge insert 102 has no moving parts. No rotating fastener, suchas a screw, bolt or pin, is used to hold wedge insert 102 in place inslot 109.

FIG. 19 illustrates that first wedge insert 102 has a first wedge angleformed between the outer slanted surface 128 and the vertical edges ofinsert tongues 126-127. First slot 109 forms a first slot angle betweenthe inner slanted surface 124 and first side 117 that is approximatelyequal to the first wedge angle. Because the first wedge angle equals thefirst slot angle, the slanted edges of the insert tongues 126-127 makecontact all along the inner slanted surface of first slot 109 whilefirst wedge insert 102 is lodged in first slot 109.

FIGS. 18-19 show that insert tongue 127 is not directly attached to theinner side 134 of lateral bar 94. Instead, insert tongue 127 is weldedto the upper portion of bent plate 125. Then bent plate 125 is welded tothe inner side 134 of lateral bar 94. FIG. 19 shows two locations wherethe upper portion of bent pate 125 is welded to the inner side 134. Inone embodiment, a hook is disposed at the bottom of the outer slantedsurface 128 of first wedge insert 102. First wedge insert 102 snaps intofirst slot 109 when the hook catches on the lower edge of slanted side123 of first slot 109 when the wedge is completely inserted into theslot.

FIG. 19 also shows that lateral bar 94 is hollow and has a rectangularcross section. In fact, all of the lateral and longitudinal bars 94-97and the support legs 98-101 are made from hollow, rectangular metalbars. The hollow, rectangular metal construction of the bars provides astronger structure than would solid bars of the same weight of metal.

FIG. 20 shows the assembly step after both lateral bar 94 andlongitudinal bar 96 have been attached to support leg 98. By connectingfirst wedge insert 102 to first slot 109 and second wedge insert 103 tosecond slot 103, both lateral bar 94 and longitudinal bar 96 areconnected to support leg 98. FIG. 20 shows that first slot 109 isdisposed on first side 117 adjacent to edge 119 and that second slot 110is disposed on second side 118 adjacent to edge 119. In one embodiment,a side of slot 109 and a side of slot 110 are attached to the first andsecond sides adjacent to edge 119 using the same weld, as shown in FIG.20. Thus, first slot 109 contacts second slot 110.

In the assembled state when first wedge insert 102 is lodged in firstslot 109, first wedge insert 102 is disposed between edge 119 andlateral bar 94. The connection between wedge insert 102 and slot 109 isnot visible when viewing bed frame assembly 93 with a mattress isresting on top. In addition, second wedge insert 103 is disposed betweenedge 119 and longitudinal bar 96 while second wedge insert 103 is lodgedin second slot 110. In the assembled state, support leg 98, lateral bar94 and longitudinal bar 96 are all perpendicular to one another. Lateralbar 94 is oriented perpendicular to support leg 98 while first wedgeinsert 102 is lodged in first slot 109. Longitudinal bar 96 is orientedperpendicular to support leg 98 while second wedge insert 103 is lodgedin second slot 110. Longitudinal bar 96 is perpendicular to both leg 98and lateral bar 94 while both wedge inserts 102-103 are lodged in firstand second slots 109-110. In the assembled state, first slot 109 andsecond slot 110 are disposed adjacent to one another and between lateralbar 94 and longitudinal bar 96 while first and second wedge inserts102-103 are lodged in first and second slots 109-110. By connecting theremaining wedge inserts and slots that have matching numerals, a usercan intuitively assemble bed frame assembly 93 without usinginstructions or tools. After the eight metal components of the bed frame93 are assembled, the two rolls of wooden slats 106 are rolled out tospan between the ledges 107-108 on the longitudinal bars 96-97.

FIG. 21 shows the eight metal components of bed frame assembly 93 afterthey have been assembled and before the wooden slats 106 have beenrolled out over the ledges 107-108. In comparison to bed frame assembly20, the wedge inserts and slots are disposed inside the four lateral andlongitudinal bars instead of below the bars.

Although certain specific embodiments are described above forinstructional purposes, the teachings of this patent document havegeneral applicability and are not limited to the specific embodimentsdescribed above. Accordingly, various modifications, adaptations, andcombinations of various features of the described embodiments can bepracticed without departing from the scope of the invention as set forthin the claims.

1-28. (canceled)
 29. A bed frame assembly comprising: a support leg witha first side, a second side, a first slot and a second slot, wherein thefirst side is perpendicular to the second side and meets the second sideat an edge, wherein the first slot is disposed on the first sideadjacent to the edge, and wherein the second slot is disposed on thesecond side adjacent to the edge; a first wedge insert attached to alateral bar, wherein the first wedge insert fits into the first slot,wherein the lateral bar is oriented perpendicular to the support legwhile the first wedge insert is lodged in the first slot, and whereinthe first wedge insert is disposed between the edge and the lateral barwhile the first wedge insert is lodged in the first slot; and a secondwedge insert attached to a longitudinal bar, wherein the second wedgeinsert fits into the second slot, wherein the longitudinal bar isoriented perpendicular to the support leg while the second wedge insertis lodged in the second slot, and wherein the second wedge insert isdisposed between the edge and the longitudinal bar while the secondwedge insert is lodged in the second slot.
 30. The bed frame assembly ofclaim 29, wherein the first wedge insert has a first wedge angle, andwherein the first slot forms a first slot angle that is approximatelyequal to the first wedge angle.
 31. The bed frame assembly of claim 29,wherein the first wedge insert has two insert tongues and a bent plate,wherein the insert tongues are directly attached to the bent plate, andwherein the bent plate is directly attached to the lateral bar.
 32. Thebed frame assembly of claim 31, wherein the insert tongues fit into thefirst slot.
 33. The bed frame assembly of claim 31, wherein each of theinsert tongues has a slanted edge that contacts an inner slanted surfaceof the first slot while the first wedge insert is lodged in the firstslot.
 34. The bed frame assembly of claim 29, wherein the first wedgeinsert snaps into the first slot.
 35. The bed frame assembly of claim29, wherein the first slot has a rectangular slot opening.
 36. The bedframe assembly of claim 29, wherein the first slot is formed by a bentsheet of metal welded to the first side.
 37. The bed frame assembly ofclaim 29, wherein the first wedge insert is formed from a bent platewelded to a side of the lateral bar and insert tongues welded to thebent plate.
 38. The bed frame assembly of claim 29, wherein the firstwedge insert is held in the first slot by friction without using anyrotating fastener.
 39. A bed frame assembly comprising: a leg that has afirst slot and a second slot, wherein the first slot has a first innerslanted surface, and wherein the second slot has a second inner slantedsurface; a lateral bar that has a first wedge insert that is adapted tolodge in the first slot, wherein the first wedge insert has a firstslanted outer surface that is adapted to contact the first inner slantedsurface while the first wedge insert is lodged in the first slot; andwherein the lateral bar is perpendicular to the leg while the firstwedge insert is lodged in the first slot; and a longitudinal bar thathas a second wedge insert that is adapted to lodge in the second slot,wherein the second wedge insert has a second slanted outer surface thatis adapted to contact the second inner slanted surface while the secondwedge insert is lodged in the second slot, and wherein the longitudinalbar is perpendicular to the leg and perpendicular to the lateral barwhile both the second wedge insert is lodged in the second slot and thefirst wedge insert is lodged in the first slot.
 40. The bed frameassembly of claim 39, wherein the first slot and the second slot aredisposed between the lateral bar and the longitudinal bar while thefirst and second wedge inserts are lodged in the first and second slots.41. The bed frame assembly of claim 39, wherein the leg has a first sideand a second side that meet each other at an edge, wherein the firstslot is disposed on the first side adjacent to the edge, and wherein thesecond slot is disposed on the second side adjacent to the edge.
 42. Thebed frame assembly of claim 39, wherein the first wedge insert snapsinto the first slot.
 43. The bed frame assembly of claim 42, wherein thefirst wedge insert snaps into the first slot when a hook of the firstwedge insert catches on an edge of the first slot.
 44. The bed frameassembly of claim 39, further comprising: a second longitudinal bar thatis parallel to the longitudinal bar and perpendicular to the lateral barwhile the first and second wedge inserts are lodged in the first andsecond slots; and wooden slats that span between the longitudinal barand the second longitudinal bar.
 45. The bed frame assembly of claim 44,wherein the wooden slats are attached to one another by fabric ribbons.46. The bed frame assembly of claim 39, wherein the longitudinal bar andthe lateral bar are hollow and have rectangular cross sections.
 47. Abed frame assembly comprising: a leg with a first slot and a secondslot, wherein the first slot is oriented perpendicular to the secondslot; a first wedge insert attached to a lateral bar, wherein the firstwedge insert is adapted to fit into the first slot; and a second wedgeinsert attached to a longitudinal bar, wherein the second wedge insertis adapted to fit into the second slot, and wherein the first slot andthe second slot are disposed adjacent to one another and between thelateral bar and the longitudinal bar while the first and second wedgeinserts are lodged in the first and second slots.
 48. The bed frameassembly of claim 47, wherein the lateral bar is oriented perpendicularto the support leg while the first wedge insert is lodged in the firstslot, and wherein the longitudinal bar is oriented perpendicular to thesupport leg while the second wedge insert is lodged in the second slot.49. The bed frame assembly of claim 47, wherein the first wedge insertis formed from a bent plate welded to the lateral bar and insert tongueswelded to the bent plate, and wherein the insert tongues are adapted tofit into the first slot.